1997 JAGUAR XJ6 VIN

3Remove two bumper retaining bolts located
on the bottom side of the bumper (see
illustration). Pull the bumper assembly out
and away from the vehicle to remove it.
4Refitting is the reverse of removal.
15 Front wing-
removal and refitting
3
1Loosen the front wheel nuts. Raise the
vehicle, support it securely on axle stands and
remove the front wheel.
2Remove the front bumper assembly (see
Section 14).
3Remove the front spoiler (see Section 13).4Detach the inner wing splash shield (see
illustration).
5On 1988 and 1989 models, remove the
coolant overflow reservoir located behind the
splash shield (see Chapter 3).
6On models with round headlights, remove
the headlight bezel. On models with
composite headlights (1992 Vanden Plas, all
1993 and later models), remove the headlight
(see Chapter 12).
7Remove the wing mounting bolts and nuts
(see illustrations).
8Detach the wing. It’s a good idea to have an
assistant support the wing while it’s being
moved away from the vehicle to prevent
damage to the surrounding body panels.
9Refitting is the reverse of removal.
16 Boot lid- removal,
refitting and adjustment
2
Note:The boot lid is heavy and somewhat
awkward to remove and refit - at least two
people should perform this procedure.
Removal and refitting
1Open the boot lid and cover the edges of
the boot compartment with pads or cloths to
protect the painted surfaces when the lid is
removed.
2Disconnect any cables or wire harness
connectors attached to the boot lid that would
interfere with removal.
3Make alignment marks around the hinge
mounting bolts with a marking pen.
4While an assistant supports the boot lid,
remove the lid-to-hinge bolts on both sides
and lift it off(see illustration).
5Refitting is the reverse of removal. Note:
When refitting the boot lid, align the lid-to-
hinge bolts with the marks made during
removal.
Adjustment
6Fore-and-aft and side-to-side adjustment
of the boot lid is done by moving the bonnet in
relation to the hinge plate after loosening the
bolts or nuts.
7Scribe a line around the entire hinge plate
as described earlier in this section so you can
judge the amount of movement.
11•6 Bodywork and fittings
14.3 Remove the two retaining bolts from
the bottom of the bumper, then remove the
bumper from the vehicle15.4 Remove the bolts (arrowed) securing
the inner wing splash shield15.7a Detach the wing retaining bolts
(arrowed) at the front of the wing
15.7c Working in the wheel opening,
remove the wing-to-rocker panel bolt
(arrowed)
15.7d Remove the wing-to-door pillar bolt
(arrow; lower bolt not visible)15.7e Detach the bolts along the
top of the wing
3261 Jaguar XJ6
15.7b Remove the wing-to-radiator
support bolt (arrowed)
16.4 With the help of an assistant to hold
the boot lid, remove the retaining bolts and
lift off the boot lid

2Open the door all the way and support it on
jacks or blocks covered with rags to prevent
damaging the paint.
3Remove the door trim panel and water
deflector as described in Section 18.
4Unplug all electrical connections, ground
wires and harness retaining clips from the
door. Note:It is a good idea to label all
connections to aid the reassembly process.
5From the door side, detach the rubber
conduit between the body and the door, then
carefully pull the wiring harness through the
conduit hole and remove it from the door.
6Mark around the door hinges with a pen or
a scribe to ease alignment during reassembly.
7On front doors, work through the door
access hole to remove the hinge-to-door
nuts. On rear doors the hinge-to-body bolts
are more accessible and can be removed by
simply opening the front door and removing
the bolts (see illustrations).
8Have an assistant hold the door, remove
the bolts or nuts and lift the door off.
9Refitting is the reverse of removal.
Adjustment
10Having proper door to body alignment is a
critical part of a well functioning doorassembly. First check the door hinge pins for
excessive play. Note: If the door can be lifted
(1/16-inch or more) without the car body
moving, the hinges should be replaced.
11Door-to-body alignment adjustments are
made by loosening the hinge-to-body or hinge-
to-door bolts and moving the door. Proper
body alignment is achieved when the top of
doors are parallel with the roof section, the
front door is flush with the wing, the rear door is
flush with the rear quarter panel and the
bottom of the doors are aligned with the lower
rocker panel. If these goals can’t be reached by
adjusting the hinge-to-body or hinge-to-door
bolts, body alignment shims may have to be
purchased and inserted behind the hinges to
achieve correct alignment.
12To adjust the door closed position, scribe
a line or mark around the striker plate to
provide a reference point. Check that the door
latch is contacting the centre of the latch
striker. If not, adjust the up-and-down
position first.
13Finally, adjust the latch striker position, so
the door skin is flush with the rear door (front)
or rear quarter panel (rear) and provides
positive engagement with the latch
mechanism (see illustration).
20 Door latch, lock cylinder and
handles- removal and refitting
2
Door latch
1Raise the window, then remove the door
trim panel and watershield as described in
Section 18.
2Working through the large access hole,
disengage the outside door handle-to-latch
rod and the inside handle-to-latch cable (see
illustration).
3All door locking rods are attached by plastic
clips. The plastic clips can be removed by
unsnapping the portion engaging the
connecting rod and then by pulling the rod out
of its locating hole.
4Remove the screws securing the latch to
the door (see illustration), then remove the
latch assembly from the door.
5Refitting is the reverse of removal.
Outside handle
and door lock cylinder
6To remove the outside handle and lock
cylinder assembly, raise the window then
Bodywork and fittings 11•9
11
19.13 Adjust the door lock striker by
loosening the hex nut and gently tapping
the striker in the desired direction20.2 Detach the outside handle-to-latch
rod (A), then remove the inside handle-to-
latch cable (B)20.4 Remove the latch screws (arrowed)
from the end of the door, and pull the latch
assembly through the access hole.
3261 Jaguar XJ6 19.7a Work through the door access hole (arrowed) to remove
the hinge-to-door retaining nuts from inside the door
19.7b Open the front door to access the rear door hinge-to-body
bolts (arrowed)

remove the door trim panel and watershield
as described in Section 18.
7Working through the access hole, detach
the outside handle retaining nuts (see
illustration),then pull the handle away from
the door.
8Disengage the plastic clip that secures the
outside handle-to-latch rod (see illustration).
9Remove the handle and lock cylinder
assembly from the vehicle.
10Refitting is the reverse of removal.
Inside handle and cable
11Remove the door trim panel as described
in Section 18 and peel away the watershield.
12Detach the inside handle-to-latch cable
(see illustration 20.2).
13Remove the inside handle retaining bolts
(see illustration).
14Pull the handle and cable assembly free
and remove them from the door.15Refitting is the reverse of removal.
21 Door window glass
regulator-
removal and refitting
3
1To remove the window regulator assembly,
raise the window to its full upright position,
then remove the door trim panel and
watershield as described in Section 18.
2Tape the window to the door glass frame to
secure the window in the full upright position.
3Remove the regulator and motor mounting
bolts (see illustration).
4Disconnect the electrical connector from
the window regulator motor.
5Slide the equaliser arms out of the window
glass channel and remove the regulator and
motor assembly through the service hole in
the door frame.Warning: The regulator arms are
under pressure and can cause
serious injury if the motor is
removed without locking the
sector gear. The motor and regulator can
now safely be separated.
6Refitting is the reverse of removal.
11•10 Bodywork and fittings
3261 Jaguar XJ6 20.7 The outside handle retaining nuts (arrowed) can be reached
through the access hole in the door
20.8 Detach the plastic clip securing the lock rod
20.13 After removing the cable from the latch assembly, detach
the handle retaining bolts, then pull the handle and cable
assembly free from the vehicle21.3 Detach the window regulator bolts (arrowed)
If the motor or regulator
needs replacing, it will be
necessary to lock the sector
gear to the regulator back-
plate. This can be done by fastening the
sector gear to the backplate with a bolt
inserted through one of the holes in the
backplate and sector gear and secured
with a nut. If none of the holes line up,
drill a hole through the backplate and
sector gear.

22 Door window glass-
removal and refitting
3
1Raise the window to its full upright position,
then remove the door trim panel and
watershield as described in Section 18.
2Tape the window to the door glass frame to
secure the window in the full upright position.
3Detach the regulator assembly (Section 21)
and lower it to the bottom of the door.
4Remove the window frame retaining bolts
(see illustrations).
5Remove the window frame and glass
assembly by pulling it up and out (see
illustration).
6Refitting is the reverse of removal.
23 Outside mirrors-
removal and refitting
2
1Raise the window to the fully closed
position and remove the upper half of the
door trim panel (see Section 18).
2Detach the trim cover retaining screws (see
illustration).3Disconnect the wiring plug from the mirror.
4Remove the three mirror retaining screws
and detach the mirror from the vehicle (see
illustration).
5Refitting is the reverse of removal.
24 Centre console-
removal and refitting
3
Floor console
1Disconnect the negative battery cable.Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Pry out the gear selector trim bezel (see
illustration).
3Open the console compartment and
remove the screws securing the ash tray. Pull
the ash tray back towards the compartment to
remove it (see illustrations).
4Working through the ash tray opening,
detach the plastic wingnuts securing the rear
edge of the radio trim bezel (see illustration).
5Apply the handbrake, then move the gear
Bodywork and fittings 11•11
11
22.4a Front door window frame screws 22.4b Rear door window frame screws
22.5 After removing the window frame
retaining screws, pull the window and
frame assembly up and out to remove it
3261 Jaguar XJ6 23.2 Remove the trim cover retaining screws
23.4 Disconnect the electrical connector, then detach the three
mirror retaining screws and remove the mirror from the vehicle
24.3a Open the console compartment to
access the ash tray screws (arrowed)24.2 Carefully prise out the gear selector
trim bezel

selector towards the rear of the vehicle. Pull
up on the rear half of the radio trim bezel while
gently detaching the clips securing the front,
then remove the bezel from the vehicle.
6Remove the radio and heater control
assembly (see Chapter 12).
7Remove the dashboard centre trim panel
(see Section 26), then remove the centre air
conditioning duct from the vehicle (see
illustration).
8Remove the retaining screws located in the
air conditioning duct opening (see illustration).
9Remove the plastic screws securing the
lower front section of the console (see
illustration).
10Unplug any electrical connectors that will
interfere with the removal of the console.
11Pull the console towards the rear of the
vehicle, then lift the console up over the shift
lever and remove it from the vehicle.
12Refitting is the reverse of removal.
Overhead console
13Remove the plastic screw securing the
overhead console, then carefully pull the
console out of the headliner (see illustration).
14Disconnect the electrical connectors from
the lights.
15Refitting is the reverse of removal.
25 Instrument cluster housing-
removal and refitting
2
Warning: Later models are
equipped with airbags. To
prevent the accidental deploy-
ment of the airbag, which could
cause personal injury or damage to the
airbag system, DO NOT work in the vicinity
of the steering column or instrument panel.
The manufacturer recommends that, on
airbag equipped models, the following
procedure should be left to a dealer service
department or other repair workshop
because of the special tools and techniques
required to disable the airbag system.
1Disconnect the negative battery cable. Caution: If the stereo in your vehicle is
equipped with an anti-theft system, make
sure you have the correct activation code
before disconnecting the battery.
2Remove the drivers side knee bolster (see
Section 26).
3Place the steering wheel in the full rearward
position. If the vehicle is equipped with a tilt
column, place the steering wheel in the lowest
position.
4Remove the instrument cluster housing
screws (see illustration).
5Pull the instrument cluster housing outward
to access the electrical connections on the
backside (see illustration).
6Disconnect all electrical connections from
the backside of the cluster housing and
remove the housing from the vehicle.
7Refitting is the reverse of removal.
11•12 Bodywork and fittings
24.3b Pull the ash tray towards the rear of
the vehicle to remove it - don’t pull it
straight up24.4 Working through the ash tray opening,
remove the radio trim bezel wingnuts
(arrowed) located under the trim bezel24.7 After removing the centre trim panel,
detach the air conditioning duct
24.8 Remove the retaining screws in the
air conditioning duct opening24.9 Remove the plastic screws (arrowed)
from each side of the console24.13 Remove the plastic screw, then pull
the overhead console down and unplug
the electrical connectors
3261 Jaguar XJ6
25.4 Working in the knee bolster opening,
remove two retaining screws from each
end of the instrument cluster housing25.5 Pull outward on the instrument
cluster housing and unplug the electrical
connectors from the backside

14 Electric aerial-
removal and refitting
2
Aerial motor assembly
1Remove the aerial mast retaining nut (see
illustration).
2Working in the boot, pry out the plastic
clips securing the driver’s side boot finishing
panels to allow access to the aerial motor
assembly.
3Detach the motor assembly retaining bolts
(see illustration). Disconnect the electrical
connector and earth strap then remove the
aerial motor assembly from the vehicle.
4Refitting is the reverse of removal.
Aerial mast
5Remove the aerial mast retaining nut (see
illustration 14.1).
6With an assistant controlling the ignition
switch, turn the ignition key and the radio to
the ON position. Guide the aerial mast out of
the body as the cable unwinds from the motor
assembly (see illustration). Note the direction
the “teeth” on the aerial cable are facing for
refitting purposes.
7To refit the aerial mast, insert the aerial
cable into the motor assembly with the cable
teeth facing the direction as noted above.
Have your assistant turn the ignition key and
the radio to the ON position. Guide the cableand aerial mast through the opening as the
cable winds back into the motor assembly.
8Refit the aerial mast retaining nut.
15 Windscreen wiper motor-
removal and refitting
2
1Pull the wiper arm nut cover back to access
the wiper arm nuts. Remove the nuts and pull
the wiper arm straight off the shaft (see
illustration).
2Remove the screws and detach the cowl
cover (see Chapter 11).
3Remove the drive spindle nut (see
illustration).
4Remove the retaining bolts located along
the top edge of the wiper motor housing and
detach three retaining clips along the bottom
edge of the wiper motor housing (see
illustration).
5Disconnect the electrical connector and
remove the motor assembly from the vehicle.
6Refitting is the reverse of removal.
16 Heated rear window-
check and repair
2
1The heated rear window consists of a
number of horizontal elements baked onto the
glass surface.2Small breaks in the element can be repaired
without removing the rear window.
Check
3Turn the ignition switch and heated rear
window switches to the ON position.
4When measuring voltage during the next
two tests, wrap a piece of aluminium foil
around the tip of the voltmeter negative probe
and press the foil against the heating element
with your finger (see illustration). Place the
voltmeter positive lead against the heated
window positive terminal.
5Check the voltage at the centre of each
heating element (see illustration).
12•8 Body electrical system
14.1 The aerial mast retaining nut can be
removed with an open end spanner14.3 Remove the retaining bolts (arrowed),
pull the aerial assembly out and unplug the
electrical connectors and aerial lead14.6 With the ignition key and the radio in
the ON position, guide the aerial mast out
of the motor assembly - note the direction
of the “teeth” on the aerial cable
15.1 Lift up the wiper arm nut cover,
remove the nut and pull the wiper arm
straight off the shaft15.3 Use a spanner or socket to remove
the drive spindle retaining nut15.4 Remove the bolts (A) along the
top edge of the housing and detach the
clips (B) along the bottom edge
3261 Jaguar XJ6
16.4 When measuring the voltage at the
heated rear window grid, wrap a piece of
aluminium foil around the negative probe
of the voltmeter and press the foil against
the element with your finger

6If the voltage is 6 volts, the element is okay
(there is no break). If the voltage is 12 volts,
the element is broken between the centre
of the element and the positive end. If the
voltage is 0 volts the element is broken
between the centre of the element and earth.
7To find the break, place the voltmeter
positive lead against the defogger positive
terminal. Place the voltmeter negative lead
with the foil strip against the heating element
at the positive terminal end and slide it toward
the negative terminal end. The point at which
the voltmeter deflects from zero to several
volts is the point at which the heating element
is broken (see illustration).
Repair
8Repair the break in the element using a
repair kit specifically recommended for this
purpose.
9Prior to repairing a break, turn off the system
and allow it to cool off for a few minutes.
10Lightly buff the element area with fine
steel wool, then clean it thoroughly with
rubbing alcohol.
11Use masking tape to mask off the area
being repaired.
12Thoroughly mix the epoxy, following the
instructions provided with the repair kit.
13Apply the epoxy material to the slit in the
masking tape, overlapping the undamaged
area about 3/4-inch on either end (see
illustration).
14Allow the repair to cure for 24 hours before
removing the tape and using the system.
17 Headlights- renewal
1
Warning: Later models are
equipped with halogen gas-filled
headlight bulbs which are underpressure and may shatter if the surface is
damaged or the bulb is dropped. Wear eye
protection and handle the bulbs carefully,
grasping only the base whenever possible.
Do not touch the surface of the bulb with
your fingers because the oil from your skin
could cause it to overheat and fail
prematurely. If you do touch the bulb
surface, clean it with rubbing alcohol.
Sealed beam units
1Remove the radiator grille (see Chapter 11).
2Detach the headlight bezel trim cover (see
illustration).
3Remove the headlight bezel (see
illustrations).
4Remove the screws which secure the
retaining ring and withdraw the ring. Support
the light as this is done (see illustration).
Body electrical system 12•9
12
16.13 Apply masking tape to the inside of
the window at the damaged area, then
brush on the special conductive coating17.2 Remove the screws (arrowed) and
detach the headlight bezel trim cover
17.3a Remove the two retaining screws
at the top and the one in the grille opening
(arrowed)17.3b The retaining screw at the
outside lower corner can be accessed
from under the bumper
3261 Jaguar XJ6 16.5 To determine if a heating element has broken, check the
voltage at the centre of each element. If the voltage is 6-volts, the
element is unbroken; if the voltage is 12-volts, the element is
broken between the centre and the positive end. If there is no
voltage, the element is broken between the centre and earth
16.7 To find the break, place the voltmeter positive lead against
the heated window positive terminal, place the voltmeter negative
lead with the foil strip against the heating element at the positive
terminal end and slide it toward the negative terminal end -
the point at which the voltmeter reading changes abruptly is the
point at which the element is broken

8Adjustment should be made with the
vehicle parked 25 feet from the wall, sitting
level, the petrol tank half-full and no unusually
heavy load in the vehicle.
9Starting with the low beam adjustment,
position the high intensity zone so it is two
inches below the horizontal line and two
inches to the right of the headlight vertical
line. Adjustments are made by turning the
knobs located behind the headlight housings
(see illustration 18.2).
10With the high beams on, the high intensity
zone should be vertically centred with the
exact centre just below the horizontal line.
Note:It may not be possible to position the
headlight aim exactly for both high and low
beams. If a compromise must be made, keep
in mind that the low beams are the most used
and have the greatest effect on safety.
11Have the headlights adjusted by a dealer
service department or service station at the
earliest opportunity.
19 Headlight housing
(1992 to 1994 models)-
removal and refitting
1
Warning: These vehicles are
equipped with halogen gas-filled
headlight bulbs which are under
pressure and may shatter if the
surface is damaged or the bulb is dropped.
Wear eye protection and handle the bulbs
carefully, grasping only the base whenever
possible. Do not touch the surface of the
bulb with your fingers because the oil from
your skin could cause it to overheat and
fail prematurely. If you do touch the bulb
surface, clean it with rubbing alcohol.
1Remove the headlight bulb (Section 17).
2Remove the retaining nuts, detach the
housing and withdraw it from the vehicle (see
illustration).
3Refitting is the reverse of removal.
20 Horn- check and renewal
2
Check
Note:Check the fuses before beginning
electrical diagnosis.
1Disconnect the electrical connector from
the horn.
2To test the horn, connect battery voltage to
the two terminals with a pair of jumper wires.
If the horn doesn’t sound, renew it.
3If the horn does sound, check for voltage at
the terminal when the horn button is
depressed (see illustration). If there’s voltage
at the terminal, check for a bad earth at the
horn.
4If there’s no voltage at the horn, check the
relay (see Section 6). Note that most horn
relays are either the four-terminal or externally
earthed three-terminal type.
5If the relay is OK, check for voltage to the
relay power and control circuits. If either of the
circuits are not receiving voltage, inspect the
wiring between the relay and the fuse panel.
6If both relay circuits are receiving voltage,
depress the horn button and check the circuit
from the relay to the horn button for continuityto earth. If there’s no continuity, check the
circuit for an open. If the circuit is good, renew
the horn button.
7If there’s continuity to earth through the
horn button, check for an open or short in the
circuit from the relay to the horn.Renewal
8Remove the radiator grille inserts (see
Chapter 11).
9Disconnect the electrical connector and
remove the retaining nuts securing the horn
brackets (see illustration).
10Refitting is the reverse of removal.
21 Bulb renewal
1
Front direction indicator/rear
parking and side marker lights
1Remove the lens retaining screws and the
lens (see illustration).
2Push inward and rotate the bulb anti-
clockwise to remove it from the holder.
3Renew the bulb, refit the lamp lens and test
the bulb operation.
Body electrical system 12•11
12
20.9 Disconnect the electrical connector,
remove the retaining nuts (arrowed) - then
detach the horn(s)21.1 The front direction indicator/rear
parking and side marker light bulbs are
accessible after removing the lens screws
3261 Jaguar XJ6 19.2 Remove the headlight housing retaining nuts (arrowed) from
the backside of the radiator support
20.3 Check for power at the horn terminal with the horn button
depressed